5 spd swap?

Discussion in 'New TDI forum member introductions' started by spitdi, Jul 2, 2011.

  1. spitdi

    spitdi New Member

    Joined:
    Jul 2, 2011
    Messages:
    3
    Car:
    2002 VW Golf TDI
    Recently purchased an 02 Golf TDI with 109K, automatic :(. The 01M is beginning to bite the dust - not shifting, revving super high, etc. I would like to keep this car for at least another 150K if possible, so I am considering a 5 spd swap. Anyone have any advice on the swap/on parts? For example, durability of the 02J? Buying a rebuilt manual tranny vs a used one? Anyone in SE PA have experience or advice? Please let me know. Thanks.
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  2. chittychittybangbang

    chittychittybangbang Administrator

    Joined:
    May 23, 2007
    Messages:
    22,071
    Car:
    2006 Jetta TDI
    Location:
    CT
    On the bright side, you can reuse the ECU. Just change the coding from auto to manual.

    It's been done, you need the pedal assembly, master, slave cylinder, and lines, and transmission. Then cut a hole in the firewall for the master cylinder and done.

    I would go for a low mileage used one, it should be cheaper. I would buy a new master and slave. should be able to find pedals online cheaply as well.
  3. spitdi

    spitdi New Member

    Joined:
    Jul 2, 2011
    Messages:
    3
    Car:
    2002 VW Golf TDI
    Thanks for the prompt reply.

    I assume low mileage is under 100k or thereabouts?

    I've also heard that a Dieselgeek Short Shifter is needed for clearance purposes, do you have experience with that?

    I'm looking into the Sachs VR6/G60 clutch and flywheel kit from IDparts. Advice?


    Finally, I was wondering if you know of any more how to's other than those posted on TDIclub and those in Bentley's. I'm in the measuring twice, cut once stage of planning.

    Thanks,
    Jon
  4. chittychittybangbang

    chittychittybangbang Administrator

    Joined:
    May 23, 2007
    Messages:
    22,071
    Car:
    2006 Jetta TDI
    Location:
    CT
    under 100k is fine, the sachs vr6/g60 clutch is what I would go with - easy effort, cheap, reliable.

    I don't know why extra clearance is required since you're removing the auto trans cooler.

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